pt.3 How to full tear down and reassembly of a NP208 Transfer Case. 22 Steps

Kit partnumber: ZTBK208 Step by step teardown of Project Scar's 208 Transfercase. This Do It Yourself video walks you through the process of disassembly using the transfer case from a 1985 GMC Squarebody. Watch our Project Scar playlist for all of our Squarebody projects. 0:26 Step 1 Look over your overhaul kit to ensure you have everything you need. Remove all bearings and old seals 2:30 Step 2 Inspect all old parts for damage. Order replacements if damage is found. 3:20 Step 3 Remove all old sealant from sealing surfaces. 4:10 Step 4 Install new bearings and seals 7:02 Step 5 Apply grease to all bearings and races 7:40 Step 6 install the input shaft and thrust bearing 8:20 Step 7 Install range sector shaft toque to 14-20ft.lbs. 8:50 Step 8 Install Planetary and mode fork 10:00 Step 9 Install Syncro struts and Syncro ring 11:40 Step 10 Install main shaft assembly with mode fork 13:11 Step 11 Install 2 rows of 60 needle bearings in drive sprocket. 13:58 Step 12 Install Install chain, drive and driven sprockets with front output shaft into case with front thrust bearings. 14:34 Step 13 Apply a thin amount of sealant to case flange and marry the case halves. Ensure the shift fork spring and magnet are installed. 15:55 Step 14 Torque case halves in an alternating pattern to 20-25 ft. lbs 16:13 Step 16 Install detent ball, spring. Bolt-in front case half. Torque to 20-25 ft. lbs. 16:35 Step 17 Install oil pump components and speedo drive gear onto the output shaft. 17:04 Step 18 Install oil pump components and speedo drive gear onto the output shaft. 17:24 Step 19 Torque tail housing in an alternating pattern to 20-25 ft. lbs 18:03 Step 20 Install front and rear output seals and the input seal. Install front output flange. 18:18 Step 21 Install front output flange making sure you don't forget the new spline seal. 18:32 Step 22 Torque flange nut to 90-130ft. lbs. Subscribe for more Square Body videos and Project Scar